A231739 2040752-
Service Bulletin Details
Public Details for: A231739 2040752-
This bulletin contains repair information for when metallic particles are found in the high pressure fuel pump.
Models from 2012
2012 AUDI A3 |
2012 AUDI Q7 |
Models from 2011
2011 AUDI A3 |
2011 AUDI Q7 |
Models from 2010
2010 AUDI A3 |
2010 AUDI Q7 |
Models from 2009
2009 AUDI Q7 |
23 MIL on, no start or rough running (DTCs P0087, P0088, P0191) 23 17 39 2040752/6 February 13, 2017. Supersedes Technical Service Bulletin Group 23 number 15-37 dated November 20, 2015 for reasons listed below. Model(s) Year VIN Range Vehicle-Specific Equipment A3 2010 - 2012 All TDI clean diesel Q7 2009 - 2012 All TDI clean diesel Condition REVISION HISTORY Revision Date Purpose 6 - Revised Service (Added information on fuel sampling and analysis) Revised Required Parts and Tools (Updated part numbers) 5 11/20/2015 Revised Service (Completely revised step 5 under High pressure fuel pump replacement and fuel system repair) Revised Warranty (Added labor operation 2050 1901 under Q7) Revised Required Parts and Tools (Added Fuel delivery unit and fuel gauge sender under A3; added suction pump and updated quantity of seal rings under Q7) 4 07/17/2015 Revised Required Parts and Tools (Updated part numbers for Q7 fuel supply module) MIL on. Vehicle either runs roughly or does not start. One or more of the following DTCs is stored in the engine control module (ECM), J623 (address word 0001): DTC P0087 (Fuel rail/system pressure - too low) DTC P0088 (Fuel rail/system pressure - too high) DTC P0191 (Fuel rail pressure sensor “A” circuit range/performance) Page 1 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. Technical Background Metallic particles in the high pressure fuel pump may cause the condition. Production Solution Not applicable. Service Note: Before proceeding, perform all GFF diagnostic procedures and check all components to determine a root cause of the condition, including testing supply pressure to the high pressure fuel pump (low pressure side) and checking for internal leakage from the injectors and N276 pressure regulating valve. If no root cause can be found, use the following procedure to check for metallic particles in the high pressure fuel pump. Initial diagnosis of high pressure fuel pump: 1. Prepare to remove the N290 fuel metering valve by first cleaning the area around the valve then drying the area using compressed air (Figure 1). All debris must be removed from the area to ensure that no debris enters the fuel system and causes damage. More information is available in the Elsa Repair Manual at Engine>>Fuel Supply System>>General Repair Information>>Clean Working Conditions. Figure 1. Area surrounding N290 fuel metering valve. Page 2 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. 2. Remove the N290 fuel metering valve, and inspect both the valve and valve bore for metallic particles (Figure 2). Figure 2. N290 fuel metering valve and valve bore shown with and without metallic particles. 3. If metallic particles are found: This bulletin applies. The high pressure fuel pump and major components of the fuel system will need to be replaced. Proceed to the next section for instructions. If metallic particles are not found: This bulletin does not apply. Reinstall the N290 fuel metering valve using light pressure. Before reinstalling, ensure that the valve is free of contaminates. Install and hand-tighten both M5 fasteners, ensuring that the threads are clean and dry (pre-tighten to 2 Nm, then to 6.5 - 7 Nm). Figure 3. N290 fuel metering valve O-rings. Note: Before reinstalling the N290 fuel metering valve, check the O-rings for damage (Figure 3). If any damage is found, the high fuel pressure pump must be replaced outside of this bulletin. Page 3 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. To prevent damage to the O-rings during reinstallation of the valve, lubricate the O-rings with diesel fuel. Fuel sampling and analysis: Before any repairs are performed, a fuel sample must be taken and analyzed. Do not substitute results from the VAS6774 fuel tester. 1. Order the fuel sample kit (part number LQ1LKIT) from the Compliance Label Ordering Portal under Service in AccessAudi (Figure 4). A valid extension VIN must be used to order the kit. The fuel sample kit will be sent to the dealership within one business day (note that dealerships in Alaska and Hawaii will be contacted by Audi of America with further instructions after the kit is ordered). The fuel sample kit contains a prepaid shipping label, all necessary packaging, and instructions for sending the sample to a designated test facility. Note: HAZMAT certification is required for packaging the fuel sample, but NOT for shipping. The fuel sample can be shipped to the laboratory through ground shipment services, provided that the dealer is using the Limited Quantity Kit (PN# LQ1LKIT). Figure 4. Compliance Label Ordering Portal. Test results will be provided to the dealership within three days of receipt of the sample. Page 4 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. 2. Review the test results. The results will be marked “PASS” or “FAIL” in the comments section of the certificate of analysis (Figure 5 and Figure 6). Figure 5. Example of a clean fuel sample analysis. Figure 6. Example of a contaminated fuel sample analysis. 3. See Warranty Extension Bulletin AWA-15-05 for details regarding high pressure fuel pump coverage eligibility. Tip: Remember to include the fuel sample kit number in the repair order comments. High pressure fuel pump replacement and fuel system repair: Page 5 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. Before proceeding, check ElsaPro for the latest information and detailed instructions for removal and replacement of the components listed in this TSB. 1. Use suction pump VAS5226 to clean the fuel delivery unit and fuel tank. 2. Fill the fuel tank with five liters of fresh diesel fuel. 3. Use suction pump VAS5226 to completely drain the fuel tank. 4. Replace the in-tank fuel pump. 5. Replace the suction jet pump. 6. Following the instructions in the Elsa repair manual, replace the following components: High pressure fuel pump (note that the supply and return line orientation for the HPFP may be reversed on updated pumps installed on vehicles manufactured before 05/25/2010) High pressure fuel lines Fuel rail (with both sensors included) All fuel injectors Fuel return lines (overflow oil lines) Fuel filter Fuel filter housing Auxiliary fuel pump 7. After replacements are complete, fuel the vehicle. 8. Ensure that the fuel injector return line is properly seated and sealed. 9. Using the VAS tester, perform the “Vent Fuel System” Guided Function. See the Elsa repair manual at Engine>>Fuel Supply System>>20 Fuel Supply>>Fuel System, Bleeding for additional information. Tip: If the test plan is unavailable through Guided Functions, switch to Self Diagnosis>>Engine Electronics>>Basic Settings>>35, and perform the basic settings three times consecutively. For UDS vehicles, perform basic settings for initial fueling. 10. Once the repairs are complete, test drive the vehicle. 11. Inspect for fuel seepage at the fuel injector return line connector. If seepage is found, the condition must be corrected. Page 6 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. Warranty Claim Type: 110 – Verify Vehicle Warranty Coverage. G10 for CPO Covered Vehicles – Verify Owner. If vehicle is outside any warranty, this Technical Service Bulletin is informational only. Service Number: 2374 Damage Code: 0010 Labor Operations: For Q7: Fuel bleed 2003 0750 10 TU Fuel tank cleaned 2010 2999 50 TU Diesel fuel filter remove + reinstall 2034 1900 40 TU Supply line cleaned 2038 2999 10 TU Return line cleaned 2039 2999 10 TU 2 electric fuel pump remove + reinstall 2066 2000 190 TU Suction jet pump remove 2050 1901 + reinstall 190 TU 2 distribution rail remove + reinstall 2373 2047 130 TU 6 injector remove + reinstall 2340 2047 340 TU High-pressure pump remove + reinstall 2374 1947 220 TU Online fuel analysis 2374 0199 20 TU For A3: Page 7 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. Diagnostic Time: Fuel bleed 2003 0750 10 TU Fuel tank cleaned 2010 2999 50 TU Diesel fuel filter remove + reinstall 2034 1951 20 TU Supply line cleaned 2038 2999 10 TU Return line cleaned 2039 2999 10 TU Electric fuel pump remove + reinstall 2066 1900 110 TU Electric fuel pump (aux) remove + reinstall 2066 1902 50 TU Distribution rail remove + 2373 1912 reinstall 110 TU 4 injector remove + reinstall 2340 2012 220 TU Toothed belt remove + reinstall 1524 1912 190 TU High pressure pump remove + reinstall 2374 1962 70 TU Online fuel analysis 2374 0199 20 TU GFF 0150 0000 Time stated on diagnostic protocol (Q7: Max 80 TU) (A3: Max 70 TU) Road test prior to service No allowance procedure 0 TU Road test after service procedure 10 TU 0121 0004 Technical diagnosis at dealer’s discretion Page 8 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. (Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance details) Claim Comment: As per TSB #2040752/6 All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures Manual. Claims are subject to review or audit by Audi Warranty. Required Parts and Tools For A3: Part Number Part Description Quantity 03L130755A High pressure fuel pump 1 03L130321 Fuel line 1 03L130089 Fuel rail (sensors) 1 03L130277A Fuel injector 4 059130519 Seal ring (Fuel injector) 4 WHT000884 O-ring (Fuel injector) 4 03L130301 Pressure pipe 4 059130216C Tensioning plate (Injector) 4 3C0127400C Fuel filter/housing 1 1K0130307BH Fuel line 1 03L201360G Fuel line 1 1K0130295AQ Fuel line 1 1K0130307BK Fuel line 1 03L130301R 03L130301B 03L130301C Page 9 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. 5N0130307CC Fuel line 1 1K0919050AB Fuel delivery unit and fuel gauge sender 1 5N0906129B Auxiliary fuel pump 1 Part Number Part Description Quantity 059130755BT High pressure fuel pump 1 059130300EC Fuel line set 1 N 90770201 Spring clip 2 N 90926401 Spring clip 1 4B0422379 Spring clip 4 7L6201906A Fuel hose (return) 1 7L6201905 Fuel hose (supply) 1 7L6130295AC Fuel line (return) 1 7L6130295AT Fuel hose (supply) 1 7L6130295BB Fuel hose (return) 1 059130300DF 1 set of fuel lines 1 059130310AK Fuel line 1 059130089AM Fuel rail (left) 1 059130090AQ (MY09-10) Fuel rail (right) 1 N 0138128 Seal ring (Fuel rail/fuel line) 2 059130131H (MY09-10) Fuel line/hose 1 For Q7: 059130090BR (MY11-12) 059130218AF (MY11-12) Page 10 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher. 059130309AT Fuel line 1 059130277AM Fuel injector 6 WHT000884 O-ring (injector) 6 059130241CD Pressure pipe 6 059130216C Tensioning plate (Injector) 6 059130312K Fuel line 1 7L6127401H (MY09-10) Fuel filter 1 059103113G Sealing cap (Cylinder head cover) 6 7L6919088F (MY09-10) Fuel supply module 1 Suction pump 1 8E0919133B Seal ring (Fuel supply module) 2 7L6203491D Fuel radiator 1 1K0906089C (MY09-10) Auxiliary fuel pump 1 8T0127401A (MY11-12) 7P6919088B (MY11-12) 4L0919715B (see ETKA) 4L0919715C (see ETKA) 4L0919715D (see ETKA) Additional Information All parts and service references provided in this TSB (2040752) are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information. ©2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher. Page 11 of 11 © 2017 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.